yes. if your power system experiences a high current fault, say you drop a wrench across 2 live connections or your controller fails in a shorted state, etc, the fuse will blow. this breaks the circuit so no current can no longer flow.

yes. if your power system experiences a high current fault, say you drop a wrench across 2 live connections or your controller fails in a shorted state, etc, the fuse will blow. this breaks the circuit so no current can no longer flow.

CJ, a controller failure of that magnatude....jeeze man who would ever think......i,m glad for you and the owner at least things should be paid for.......................keep me updated..........................

I think the wiring harness is ok.
All 2 gauge cables are ok
Solenoid I suspect is good
Batteries are perfectly fine
Votage reducer good...
Motor is good and tested...

So what happened is this, the controller failed on it's own from what looks like a complete dead short internally... The controller was fused at the battery pack and the fused completely blew inside and melted as it should have saving everything else.

As I installed this all yesterday, with split lock washers. There is ZERO loose cables, everything is Super tight, in fact when looking at all connections including those on the controller, they are clean, there is zero melting or burn marks, no cables kinked or rubbing against metal....

The motor looks like hell but is only melted plastic that fell down on to the motor, i disconnected all of the cables and wired it to a separate power source, motor turns smooth and free..

So here is a link to all of the pictures.... and a close of up the actual damage...

Wow! nice pics. Did you talk to Rich or one of the guys at Alltrax yet? I hope the make it right.

I talked to rich earlier, and just sent this to Rich at Alltrax, they are good people so we need to give them a chance to respond.

Rich,

As I spoke to you this afternoon this is what I have found.... The controller in question is new.. I purchased from my supplier on the 19th.. The controller was installed yesterday. The controller is a DCX500 IQ. with a 400 amp solenoid, 2 gauge welding cable, crimped and soldered, all wire connections have lock washers, fused at the battery, pre-charge resistor and diode on the solenoid.

The cart was driven all day yesterday without issues. Charged overnight, drove this morning, charged today and then caught fire this afternoon while driving, it was not being pushed hard as it was simply crossing the street with a mother driving her 5th grader and infant home from school.

The fire department documented in their report a failed controller. I have brought the cart back to my shop and have done a thorough and complete inspection. Fire started inside the controller, from what I suspect is a complete dead short. The fuse at the battery pack blew saving the a more catastrophic failure. Upon close inspection.. There are no damaged or kinked cables, all cable sheath is intact. The solenoid has zero hot spots, all connections, on the batteries, solenoid and even the controller itself are tight and not burned, in fact, in one picture you can see that cables that connect to the controller did not melt any plastic or have any burn marks, further ruling out the cabling or install issues. All batteries were tested, no issues, all batteries are fully charged and the pack is at 51 volts, the motor is perfect, it looks like hell from the plastic melting and dropping on it, but I disconnected all cables from the motor and connected it to an external power source, the motor turns the tires just fine, no issues, no noise, no heat marks, just zero issues.

So what we have is a complete failure of an new controller, not an install issue, motor issue, solenoid or battery issue.

So what we need to know is what Alltrax is going to do about this and the damage to the rest of the cart.